Modular Outdoor Cooking System

ABSTRACT

A modular outdoor cooking system having a base, a lid pivotally connected to the base, and a set of cooking components. The cooking components include a charcoal grate component, a gas burner component, and a grill rack component. The base includes a series of first horizontal supports extending from an inner surface of a first side panel and a series of second horizontal supports extending from an inner surface of a second side panel. The first side panel is parallel to the second side panel. Each first horizontal support is vertically aligned with a second horizontal support creating aligned pairs of horizontal supports. The base also includes an upper support ledge extending along the first and second side panels and a back panel. Each cooking component may be temporarily positioned on an aligned pair of horizontal supports or the upper support ledge for adjustable cooking methods.

BACKGROUND OF THE INVENTION

The present invention relates to a modular outdoor cooking system.

SUMMARY OF THE INVENTION

A modular outdoor cooking system including a base, a lid pivotally connected to the base, and a set of cooking components. The base may include a back panel, a first side panel operatively connected to the back panel, and a second side panel operatively connected to the back panel. The base may also include a series of first horizontal supports extending from an inner surface of the first side panel and a series of second horizontal supports extending from an inner surface of the second side panel. The first side panel may be parallel to the second side panel. Each of the first horizontal supports may be vertically aligned with one of the second horizontal supports forming a series of aligned pairs of horizontal supports. Each of the cooking components may be dimensioned to slide onto one of the aligned pairs of horizontal supports. The set of cooking components may include a heating source component and a cooking tool component.

The base may also include an upper support ledge extending along the back panel, the first side panel, and the second side panel. The upper support ledge may be dimensioned to receive one of the cooking components or a cooking tool.

The cooking components may include two heating source components, which may include a charcoal grate component and a gas burner component. The cooking tool component may include a grill rack component. The grill rack component may have a hook dimensioned to engage a slot in the upper support ledge. The cooking tool may include a wok, a deep fryer, a griddle, a large pot, a rack for holding an infusion pan, an infusion pan, a rotisserie unit, and a wood chip plate or box.

The base may further include a first door pivotally connected to the first side panel. The base may also include a second door pivotally connected to the second side panel.

The lid may include an outwardly pivoting front panel. The lid may also include a temperature gauge and a smoke stack. A lid stop may be operatively connected to the back panel for supporting the grill lid in an open position.

The base may include a first pair of legs operatively attached to an outer edge of each of the first side panels and a second pair of legs operatively attached to an outer edge of each of the second side panels. The first and second pair of legs may each have a lower end. The lower end of each of the first pair of legs may have a wheel operatively connected thereto. The lower end of each of the second pair of legs may have a wheel operatively connected thereto. The wheels operatively connected to the second pair of legs may have a wheel base smaller than a wheel base of the wheels operatively connected to the first pair of legs. The wheels operatively connected to the second pair of legs may each have a locking means.

A support bracket may be operatively connected to one of the legs, an outer surface of the first side panel, or an outer surface of the second side panel. The support bracket may be dimensioned to engage a support bar of a side accessory. The side accessory may include a side shelf, a side table, or an accessory modular frame. The modular outdoor cooking system may further include a gas container hanger operatively connected to the outer surface of the first side panel or the outer surface of the second side panel. The gas container hanger may be dimensioned to receive a gas container. The modular outdoor cooking system may further include a guide operatively connected to one of the legs. The guide may be dimensioned to receive a gas line.

The accessory modular frame may include an accessory back panel, a first accessory side panel operatively connected to the accessory back panel, and a second accessory side panel operatively connected to the accessory back panel. The accessory modular frame may also include a series of first accessory horizontal supports extending from an inner surface of the first accessory side panel, and a series of second accessory horizontal supports extending from an inner surface of the second accessory side panel. The accessory modular frame may further include an accessory upper support ledge extending along the first accessory side panel, the back panel, and the second accessory side panel. The first accessory side panel may be parallel to the second accessory side panel. Each of the first accessory horizontal supports may be vertically aligned with one of the second accessory horizontal supports forming a series of aligned pairs of accessory horizontal supports. The series of aligned pairs of accessory horizontal supports may be spaced to slidingly receive each of the cooking components. The accessory upper support ledge may be dimensioned to receive one of the cooking components or a cooking tool.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of an embodiment of the modular outdoor cooking system.

FIG. 2 is a side view of the system.

FIG. 3 is a cross-sectional view of the system shown in FIG. 2 taken along lines 3-3.

FIG. 4 is an exploded view of a grill rack component of the system.

FIG. 5 is an exploded view of a charcoal grate component of the system.

FIG. 6 is an exploded view of a gas burner component of the system.

FIG. 7 is an exploded view of the deep fryer component of the system.

FIG. 8 is an isometric view of the system with a deep fryer component in place on the grill rack component.

FIG. 9 is a cross-sectional view of the system shown in FIG. 8 taken along lines 9-9.

FIG. 10 is an isometric view of the accessory modular frame component of the system.

FIG. 11 is a front-side view of the accessory modular frame component shown in FIG. 10.

FIG. 12 is an isometric view of the system with the accessory modular frame component attached thereto.

FIG. 13 is a cross-sectional view of the system shown in FIG. 12 taken along lines 13-13.

FIG. 14 is a cross-sectional view of the system with the side table component attached thereto.

FIG. 15 is an isometric view of the system with a griddle component.

FIG. 16 is an isometric view of the system with a rotisserie component.

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIGS. 1-3, modular outdoor cooking system 2 may include base 4 and multiple removable cooking components. Base 4 may include first (or right) side panel 6, second (or left) side panel 8, and back panel 9 supported by legs 10. Panels 6, 8, and 9 may be constructed of any type of sheet metal appropriate for use with a grill or outdoor cooker (e.g., aluminum or steel). Back panel 9 may have a length of approximately 24.5 inches. First and second side panels 6 and 8 may have lengths of approximately 20 inches. Back panel 9 and first and second side panels 6 and 8 may have heights of approximately 27 inches. First side panel 6 may be parallel to second side panel 8. Legs 10 may be constructed of 1 inch square tubing. Wheel 11 may be attached to a bottom end of one or more legs 10 for transporting system 2. Wheel 11 may have an 8 inch diameter. Alternatively, system 2 may have no wheels attached to legs 10. In another alternative embodiment, legs 10 may be designed to operate both with and without removable wheels. In yet another embodiment, legs 10 on the left side of system 2 may have wheels 11 with a larger wheel base than wheels 15 on legs 10 of the right side of system 2. In this embodiment, wheels 15 having the smaller wheel base may each be equipped with a locking means to lock the wheels 15 in place to prevent their rotation and thereby prevent system 2 from rolling.

Base 4 may also include first door 12 and second door 13 each having handle 14. First and second doors 12 and 13 may be constructed of any type of metal appropriate for use with a grill or other outdoor cooker (e.g., aluminum or steel), and may have widths of 12 inches and heights of 26 inches. Handle 14 may be constructed of a stainless steel bar with a 1 inch diameter.

Referring still to FIGS. 1-3, system 2 may also include lid 18. Lid 18 may be constructed of any type of metal appropriate for use with a grill or other outdoor cooker (e.g., aluminum or steel), and may have a height of 12 inches, a width of 24.5 inches, and a depth of 20 inches. With lid 18 in a closed position (as shown in FIGS. 2 and 3) system 2 may have an overall width of 24.5 inches, an overall depth of 25.5 inches, and an overall height of 51.25 inches. Temperature gauge 20, smoke stacks 22, and handle 24 may be attached to lid 18. Smoke stacks 22 may extend 3 inches above the top of grill lid 18, and may be cylindrically shaped with a 2.5 inch diameter. Handle 24 may be constructed of a stainless steel bar with a 1 inch diameter.

As seen in FIG. 2, lid 18 may include pivoting front panel 26 which may be moved independently of the remainder of lid 18. Movable front panel may have a height of 6 inches and may extend across the entire width of lid 18. Movable front panel 26 may be attached to the remainder of lid 18 with any pivoting mechanism, such as hinges. System 2 may further include lid stop 27 for supporting lid 18 in an open position. Lid stop 27 may be attached to back panel 9. The upper end of lid stop 27 may be positioned ¼ inch below the top of back panel 9, extend 2.5 inches from back panel 9, and have a height of 7 inches.

As shown in FIGS. 3, 8, 9 and 13, base 4 may further include a plurality of side brackets attached to legs 10 and side panels 6 and 8 for attaching side accessories to sides of base 4. Support brackets 28 may be attached to each of legs 10 for supporting a side accessory (e.g., a surface or tool) such as shelves 30. Support brackets 28 may be constructed of 0.75 inch or 1 inch square tubing. Support brackets 28 may be positioned 4 inches below the top of each leg 10, and have a height of 4 inches. This size selection may depend on the intended side accessory. In one embodiment, support bracket 28 on one side of base 4 is constructed of 1 inch square tubing and support bracket 28 on the other side of base 4 is constructed of 0.75 inch square tubing to allow for connectivity with different side accessories. Support bracket 32 may be attached to each side panel 6 and 8 for supporting gas container hanger 34. Support bracket 32 may be positioned 11.25 inches below the top edge of first and second side panels 6 and 8. Gas container hanger 34 may be constructed of 0.75 inch square tubing. Gas container hanger 34 may have a height of 20 inches and may extend 5 inches from first and second side panels 6 and 8. A container of any gaseous fuel (e.g., butane or propane) may be supported by gas container hanger 34 (as shown in FIG. 3).

With reference to FIGS. 1, 3, 4-9 and 13, the removable components may include heat source components such as charcoal grate component 38 and gas burner component 40. The removable components may further include cooking components such as grill rack component 42. Base 4 may further include a series of first horizontal supports 44 and a series of second horizontal supports 45. The first horizontal supports 44 may extend from an inner surface of first side panel 6, and second horizontal supports 45 may extend from an inner surface of second side panel 8. Each first horizontal support 44 is vertically aligned with a second horizontal support 45 forming aligned pairs of horizontal supports 44 and 45 for supporting removable components at various levels within base 4. Each of first and second horizontal supports 44 and 45 may extend 1.5 inches from the inner surface of first and second side panels 6 and 8 respectively. Aligned pairs of horizontal supports 44 and 45 may be spaced 4 inches from one another on first and second side panels 6 and 8. Each first horizontal support 44 may be an L-shaped bracket attached to the inner surface of first side panel 6. Each second horizontal support 45 may be an L-shaped bracket attached to the inner surface of second side panel 8.

Base 4 may also include upper support ledge 46 extending along first side panel 6, second side panel 8, and back panel 9 for supporting removable components at a top level of base 4. Upper support ledge 46 may extend 1.5 inches from first side panel 6, second side panel 8, and back panel 9. In FIG. 1, grill rack component 42 is supported by upper support ledge 46, while charcoal grate component 38 and gas burner component 40 are each supported by an aligned pair of horizontal supports 44 and 45. System 2 allows grill base 4 to be used with any combination of a heat source component (e.g., charcoal grate component 38 or gas burner component 40) and a cooking tool (e.g., grill rack component 42) by slidingly inserting the desired removable components into base 4 along an aligned pair of horizontal supports 44 and 45 or onto upper support ledge 46. When using gas burner component 40, charcoal grate component 38 may be used as a drip pan by placing charcoal grate component 38 on a lower aligned pair of horizontal supports 44 and 45 than gas burner component 40.

FIG. 4 illustrates an embodiment of grill rack component 42, which includes plurality of bars 48 supported by base 50. Handle 52 is attached to a front face of base 50 for sliding grill rack component 42 onto upper support ledge 46 or any aligned pair of horizontal supports 44 and 45. Hooks 53 on each side of grill rack component 42 extends below base 50 to engage a slot (analogous to slot shown in FIG. 1) in each side of upper support ledge 46 for accurately positioning and locking grill rack component 42 in place. Grill rack component 42 may have an overall width of 23.5 inches and an overall depth of 18 inches. Bars 48 may be constructed of ¼ inch diameter stainless steel rods. Base 50 may be constructed of 1 inch square tubing. Hooks 53 may be constructed of 0.25 inch diameter round bars. The slot in each side of upper support ledge 46 may extend 1 inch toward first and second side panels 6 and 8.

FIG. 5 illustrates an embodiment of charcoal grate component 38, which includes bottom plate 54, side plates 56, and grate 58 suspended by beam 60. Handle 62 is attached to the front side plate 56 for sliding charcoal grate component 38 onto any aligned pair of horizontal supports 44 and 45 or upper support ledge 46. Charcoal grate component 38 may have an overall width of 23.5 inches, an overall depth of 18 inches, and an overall height of 2 inches. Grate 58 may be formed of expanded metal.

FIG. 6 illustrates an embodiment of gas burner component 40, which includes base 64 with inner supports 66 attached thereto. Base 64 may be constructed of ¼ inch square tubing, and may have a width of 23.5 inches and a depth of 19.5 inches. Inner supports 66 may be formed of metal bar having a thickness of 1 inch and a width of 0.25 inches. Shield panels 68 are attached to inner supports 66 and burner support 69. Burner support 69 may be formed of metal bar having a thickness of 1 inch and a width of 0.25 inches. Burner support 69 may be positioned 6 inches below base 64. Gas burner 70 may be attached to burner support 69 below inner supports 66. Gas burner 70 may be constructed of cast iron or any other metal appropriate for high temperature operations. Gas burner component 40 may further include gas hose connection 72, gas flow control 74, and spark wire 76. Gas flow control 74 may include hinged cap 78. Gas line 80 may be attached to gas hose connection 72 to provide fuel for gas burner 70. In an alternative embodiment, gas burner component 40 may include plate 16 for holding wood chips. This plate may have be a 12 inch square plate. Plate 16 could also be made in the form of a box container for the wood chips.

FIG. 7 shows an embodiment of deep fryer tool 83. Tool 83 is designed to contain cooking oil for deep frying food. The cooking oil may be heated by gas burner component 40 or by charcoal or other heating source using charcoal grate component 38. Tool 38 includes oil containing compartment 122 with an upper V-shaped opening that accommodates lid 124. Lid 124 has lifting handle 125. L-shaped side arms 126 extend on each side of compartment 122. Each arm 126 includes lifting handle 84. Compartment 122 may include a plug and drain hole at the bottom thereof to drain the used cooking oil.

In FIG. 9, system 2 is configured with gas burner component 40 slidingly positioned on an aligned pair of horizontal supports 44 and 45. Charcoal grate component 38 is removed but could be positioned on a lower aligned pair of horizontal supports 44 and 45 to serve as a drip pan or otherwise for storage of charcoal grate component 38.

As shown in FIG. 9, gas flow control 74 is positioned external to right side panel 6 through a recess therein. Alternatively, side panel 6 could be made with a retractable panel for the selective placement and extension of gas flow control 74.

Referring again to FIGS. 8 and 9, gas container 82 is supported by support bracket 32 and gas container hanger 34 on the side of base 4. Gas line 80 may extend through guide 36 such that gas line 80 remains near base 4. Deep fryer tool 83 is suspended from upper support ledge 46 by arms 126 of deep fryer tool 83. Grill rack component 42 is not but may be stored on a lower aligned pair of horizontal supports 44 and 45. Alternatively, grill rack component 42 or another cooking tool (e.g., a wok, griddle, or large pot) may be placed on upper support ledge 46 for cooking in this configuration.

In an alternate embodiment, gas burner component 40 may be placed on upper support ledge 46 and another cooking tool (e.g., a wok, griddle, or large pot) may be placed on gas burner component 40 for cooking. In this alternate configuration, the cooking tool may be supported by inner supports 66 of gas burner component 40.

System 2 may also be configured to function as a smoker. In this configuration, the food to be smoke may be placed on grill rack component 42 and a heat source supplied to cause smoke that will penetrate and cook the food. Doors 12, 13 would be closed to contain the smoke within the interior of system 2. Charcoal grate component 38 may be used to support burning charcoal that will act as the heat and smoke source. Alternatively, gas burner component 40 could be used as the heat source directing the heat to a smoke source such as wood chips contained on plate 16 or in a wood chip box set within system 2. Plate 16 or the wood chip box and wood chips could also be used with charcoal as the heat source.

It is to be understood that while certain components or cooking tools have been described herein such as deep fryer tool 83, other cooking tools can be used with system 2, as for example, an infusion pan and a rack for holding the pan, a rotisserie unit 136, a wood chip plate 16 or box, and the like.

FIGS. 10-13 illustrate another alternate embodiment of system 2 that includes accessory modular frame 86. Accessory modular frame 86 may include first accessory side panel 88, second accessory side panel 90, and accessory back panel 92. First accessory side panel 88 and second accessory side panel 90 are parallel. First accessory side panel 88 and second accessory side panel 90 may have lengths of 20 inches and heights of 12 inches. Accessory back panel 92 may have a length of 24 inches and a height of 12 inches. Panels 88, 90, and 92 may be constructed of any type of sheet metal appropriate for use with a grill or other outdoor cooker (e.g., aluminum or steel). One or more suspension caps 94 may be affixed to first accessory side panel 88 such that each suspension cap 94 fits over support bracket 28 which is affixed to leg 10 on second side panel 8 of base 4. In one embodiment, suspension caps 94 are formed of 1 inch square tubing and support brackets 28 affixed to legs 10 on second side panel 8 are formed of 0.75 inch square tubing. Suspension caps 94 and support bracket 28 may be attached by any fastening mechanism such as bolt or screw. In this way, accessory modular frame 86 is linked to base 4 of system 2.

Accessory side panels 88, 90 and accessory back panel 92 may be connected by accessory upper support ledge 96. Suspension caps 98 may be affixed to second accessory side panel 90. Accessory legs 100 may be attached to suspension caps 98 to support accessory modular frame 86. In one embodiment, suspension caps 98 are formed of 1 inch square tubing and accessory legs 100 are formed of 0.75 inch square tubing. Accessory legs 100 and suspension caps 98 may be attached by any fastening mechanism such as bolt or screw. Accessory support bracket 102 may be affixed to each of suspension caps 98 so that other tools may be linked to accessory support bracket 102 in the same way as with support bracket 28.

A series of first accessory horizontal supports 104 may extend from an inner surface of first accessory side panel 88. A series of second accessory horizontal supports 105 may extend from an inner surface of second accessory side panel 90. Each first accessory horizontal support 104 is vertically aligned with a second accessory horizontal support 105 forming aligned pairs of accessory horizontal supports 104 and 105 for supporting the removable components at various levels within accessory modular frame 86. Each of first and second accessory horizontal supports 104 and 105 may extend 1.5 inches from the inner surface of first and second accessory side panels 88 and 90 respectively. Aligned pairs of accessory horizontal supports 104 and 105 may be spaced 4 inches from one another on first and second accessory side panels 88 and 90. Each first accessory horizontal support 104 may be an L-shaped bracket attached to the inner surface of first accessory side panel 88. Each second horizontal support 105 may be an L-shaped bracket attached to the inner surface of second accessory side panel 90. Heat source components such as charcoal grate component 38 and gas burner component 40 and/or cooking components such as grill rack component 42 and deep fryer component 83 may be placed on aligned pairs of accessory horizontal supports 104 and 105 or on accessory upper support ledge 96 for cooking in the same manner as with base 4.

FIG. 14 illustrates yet another alternate embodiment of system 2 that includes side table 106. Side table 106 may include two support bars 108 positioned below table surface 110. Table surface 110 may have a length of 48 inches and a width of 19.25 inches. Each support bar 108 may include curved end 112 which engages with support bracket 28 to link side table 106 to base 4. In one embodiment, each support bar 108 is formed of 0.75 inch square tubing and support bracket 28 is formed of 1 inch square tubing. Curved end 112 and support bracket 28 may be attached by any fastening mechanism such as bolt or screw. Upper end 114 of each of table legs 116 may be rotatably attached to support bars 108. Each folding brace 118 may be attached to a central portion of support bars 108 and a central portion of table legs 116 to provide further support for side table 106. Side table 106 may further include chopping surface 120 affixed to table surface 110. Chopping surface 120 may have a length of 24 inches and a width of 16 inches.

FIG. 15 shows griddle component 132 in place on ledge 46 of system 2. Griddle 132 includes cooking plate 133 surrounded on three sides with ridge 135. Ridge 135, among other functions, is designed to contain the grease that may be used during grilling. Handle 134 placed on ridge 135 at the left and right side of griddle component 132 are used for lifting and placement of griddle component 132.

FIG. 16 reveals rotisserie component 136 of system 2. Motor unit 138 operatively engages one end of the rotisserie skewer to rotate the skewer. The other end of the skewer is retaining in retaining member 140 that has a U-shaped cutout for receiving and supporting the end of the skewer. Member 140 may be detachably affixed to ledge 46 or other components of system 2.

While preferred embodiments of the present invention have been described, it is to be understood that the embodiments are illustrative only and that the scope of the invention is to be defined solely by the appended claims when accorded a full range of equivalents, many variations and modifications naturally occurring to those skilled in the art from a review hereof. 

1. A modular outdoor cooking system comprises: a base comprising a back panel, a first side panel operatively connected to said back panel, a second side panel operatively connected to said back panel and parallel to said first side panel, a series of first horizontal supports extending from an inner surface of said first side panel, and a series of second horizontal supports extending from an inner surface of said second side panel, wherein each of said first horizontal supports is vertically aligned with one of said second horizontal supports forming a series of aligned pairs of horizontal supports; a lid pivotally connected to said base; a set of cooking components comprising a heating source component and a cooking tool component, wherein each of said cooking components is dimensioned to slide onto one of said aligned pairs of horizontal supports of said base.
 2. The system of claim 1 wherein said base further comprises an upper support ledge extending along said back panel, said first side panel, and said second side panel, and wherein said upper support ledge is dimensioned to receive one of said cooking components or a cooking tool.
 3. The system of claim 2 wherein said set of cooking components comprises two heating source components.
 4. The system of claim 3 wherein said heating source components comprise a charcoal grate component and a gas burner component, and said cooking tool component comprises a grill rack component.
 5. The system of claim 4 wherein said grill rack component comprises a hook dimensioned to engage a slot in said upper support ledge.
 6. The system of claim 4 wherein said cooking tool comprises a wok, a deep fryer, a griddle, a large pot, an infusion pan, a rotisserie unit, or a wood chip plate or box.
 7. The system of claim 1 wherein said base further comprises a first door pivotally connected to said first side panel.
 8. The system of claim 7 further comprising a second door pivotally connected to said second side panel.
 9. The system of claim 1 wherein said lid comprises an outwardly pivoting front panel.
 10. The system of claim 1 wherein said lid comprises a temperature gauge and a smoke stack.
 11. The system of claim 1 further comprising a lid stop operatively connected to said back panel for supporting said lid in an open position.
 12. The system of claim 1 wherein the base further comprises a first pair of legs operatively attached to an outer edge of each of the first side panels and a second pair of legs operatively attached to an outer edge of each of the second side panels.
 13. The system of claim 12 wherein the first and second pair of legs each have a lower end, and wherein the lower end of each of the first pair of legs has a wheel operatively connected thereto.
 14. The system of claim 13 wherein the lower end of each of the second pair of legs has a wheel operatively connected thereto.
 15. The system of claim 14 wherein the wheels operatively connected to the second pair of legs have a wheel base smaller than a wheel base of the wheels operatively connected to the first pair of legs.
 16. The system of claim 15 the wheels operatively connected to the second pair of legs each have a locking means.
 17. The system of claim 12 further comprising a support bracket operatively connected to one of said legs, an outer surface of said first side panel, or an outer surface of said second side panel, wherein said support bracket is dimensioned to engage a support bar of a side accessory.
 18. The system of claim 17 wherein said side accessory comprises a side shelf, a side table, or an accessory modular frame.
 19. The system of claim 18 wherein said accessory modular frame comprises: an accessory back panel; a first accessory side panel operatively connected to said accessory back panel; a second accessory side panel operatively connected to said accessory back panel; a series of first accessory horizontal supports extending from an inner surface of said first accessory side panel; a series of second accessory horizontal supports extending from an inner surface of said second accessory side panel; and an accessory upper support ledge extending along said back panel, said first accessory side panel, and said accessory second side panel; wherein said first accessory side panel is parallel to said second accessory side panel, and each of said first accessory horizontal supports is vertically aligned with one of said second accessory horizontal supports forming a series of aligned pairs of accessory horizontal supports; wherein said series of aligned pairs of accessory horizontal supports are spaced to slidingly receive each of said cooking components; and wherein said accessory upper support ledge is dimensioned to receive one of said cooking components or a cooking tool.
 20. The system of claim 17 further comprising: a gas container hanger operatively connected to said outer surface of said first side panel or said outer surface of said second side panel; and a guide operatively connected to one of said legs; wherein said gas container hanger is dimensioned to receive a gas container, and wherein said guide is dimensioned to receive a gas line. 